Process of and apparatus for making of fluxing materials



J. LUND April 26, 1927.

PROCESS OF AND APPARATUS FOR MAKING OF FLUX ING MATERIALS Filed Oct.

111,1 ,11,1 1111 II I Patented Apr. 26, 1927.

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- at s JOELiLUND, OF SAN FRANCISCO, CALIFORNIA.

rnoonss or AND APPARATUS FOR MAKING or FLUXING Mariam-Ans.-

Application filed 0ctobero23, 1920. Serial No.,418,9-fl7,.

. carburi'zing material of suitable chemical composition, and a method of-preparing the same, for repeated use in metallurgical processes, especially where it is desirable to use fluid fuel in place of solid carbon.

The invention also contemplates the use of said material as a purified slagging element in processes where solid carbon is usual asfuel.

As the carrying out of my invention in-v volves primarily theuse of a moltensiliceous substance such as blast furnace slag or the like,I can use for the production of this, as well as for the metallurgial process itself, any desirable form of furnace having preferably an upright shaft, and a closed top provided withmeans for charging material into the shaft, and provided also with suitable outlets for the gases and products of combustion. The lower part of the furnace is provided withsuitable tuyeres, connected with a source of supply of hot air and gas or gaseous hydrocarbons under pressure, and with means whereby the molten products coming from the. zone of fusion can be conducted away as formed.

The furnacetherefore in which the molten 1 slag is produced is preferably the sameas the one in whichthe regular smelting process is carried out with this difference in operation, to begin with, that I charge the furnace with ore, solid fuel and flux in the usual manner, smelt this down, and withdraw the contents in the usual way, until sufficient slag is accumulated to operate with according to my invention. There being a heated fore-hearth adjacent to the furnace -proper, the molten metal, or a part of the same, is tapped into this. as is also the slag, which, resting on top of the metal, is blown with steam and air when necessary for the purificationof the same.

As the slag, or as much of it as is needed, is used over and over again for fiuxing and other purposes, this tends to an accumulation in the same of injurious elements, such as sulphur and phosphorus, unless means are rn'ovided whereby these may be eliminated from said slag.

- My treatment is effective to this end, and i the amount of steaming necessary will be determined by analyzing the metal and slag produced from certain materialsof known composition. In cases Wherev the materials entering the process are comparatively free from obnoxiouselements or Where the presence ofsuch elements does no harm, I may omit the steaming of the, slag altogether.

As the treated slaghas to be puffed where it is to be used to hold up the charge'in place of coke in the furnace, it is desirable not to use lime in excess in the charge of flux, as this weakens the structure of the puffed, slag, but, when it is necessary for special reasons to usesuch lime, then it is preferable to puif the slag with air or steam 1 andsubmit the puffed-slag to the alkaline solution after the hydrocarbon has been coked in the same;

How this and the process as ordinarily carried out can be accomplished through the same mechanical means will be shownfurther on.

' The slag produced being qualified through a process of purification and added material, either basic or acid, to act as a flux repeatedly in the proces s'of smelting, I do not Wish to limit myself to the use of lime only as a flux, though this is cheap, as fluorspar or I chlorides and carbonates of other alkaline earths or alkali metals may be used to advantage, with or without lime;

My invention will be explained in detail, and further features thereof pointed out in connection with the accompanying drawings which illustrate an apparatus which may be used to advantage to practice said method. I I V p In said drawing, Figure 1 is a vertical sectional view of the apparatus; Figure 2 is. a front view of a water-cooled slag cutter which divides the slag as it flows out from a slaghopper. I I

A, furnace chamber 3, preferably of the reverberatory type, is heated, through a burner 7 or in any other way, suflicientlyto keep the slag 3 in a hot molten condition,

said slag resting on a molten metallic bath 3 which may be tap'pedthrough an opening a. The slag runs into the furnace chamber products being withdrawn through a chim- The flow of said material into the slag is regulated by the speed of a feed screw 22, also by the opening or closing of a gate 13. As the molten slag runs out of the hopper 11 onto a metallic table 17, it is puffed by fluid under pressure that is supplied through a hollow member 21 and a'supply pipe 24, the'edges of said hollow'member being fitted steam-tight against the under side of the table 17 a portion ofwhich at this point is perforated, as shown at 20 so asto admit the passage of said fluid under pressure to be forced into the slag, thus putting the same.

As the molten slag runs out on the table 17, it is further moved by an endless metallic belt 17, having transverse metallic bars 17 and which runs on, and is, moved by, drums 1823, said belt being cooled by passing through a trough 19, filled preferably with a solution of a carbonate, which keeps the metal from corroding at the same time that the belt is being cooled. As it moves the slag is'sub-divided by a cutter 14, which is hollow and contains an aqueous solution'supplied through a pipe 14 and which is forced through perforations 16 in main and branch knives constituting said cutter, thus keeping said knives cool and wet and adding moisture to putt the slag. The slag cutter is actuated vertically by a cam 15 which may be revolved by a differential speed mechanism in any well known manner. The amount of moisture or fluid necessary to cool and puff the slag sufliciently, so that the slag blocks, when out out, may remain-intact, is regulated by the pressure on the supply pipes, and also by valves 6, 0. s

As the. subdivided slag reachesthe drum 23, it is delivered into a breaker 25, having rolls 27 soarranged as to 1 merely separate such slag olocks as may still adhere together. From the breaker 25, this slag passes down a chute 26, which dips into a cistern 29, in which is contained an alkaline solution, through which the hot slag is carried by an elevator 30 and delivered into a compartment 31 for further treatment. The puffed slag is maintained as hot as practicable while passing through the solution in the compartment 29, in order that water taken up may be evaporated as quickly as possible beforecthe slag'is'delivered into the compartment 3'1. It is, seen that by this treatment, the solution is carried into the pores of the slap; remaining there, while the water passes off as steam and is withdrawn v through an opening 38. The compartment 31 into which the pulied slag is delivered is filled to I a' greater or less eXtent with petroleum heated by means of asteam coil 31 or, when the process 1s in operation for a tlme, by the heat still retained by the slag delivered thereto,

32 carries the slaginto a position to be deliv- 'ered into compartment 36 through a chute 33, said compartment 36'beingalso' filled able gas holder to befused for various pur- .with an alkaline solution, but not in com- 7 poses. The heated oil as it runs ofi the-slag,

sliding down the under side 34 of the compartment 31 is gathered in channels 35 in said under side 34 of said compartment which lead it back into the oil compartment 31, said channels passing on opposite sides of the opening 33 through which the slag falls into the compartment 36 The treated slag is now carried by an elevator 42 and delivered into a car. 47 tobe carried to a coke oven or other suitable vessel (not shown) where the volatile elements of the oil are expelled, or. what is the same thing, the petroleum is coked in thepores of the slag.

Should the slag or petroleum used contain much sulphur or other impurities it may be still further treated. by being immersed in brine for a longer or shorter period. Compartment '45 containing said brine 46 is conveniently located'for this purpose.

. lVhen it is desirable, as, forinstance,'when the slag is strong in lime, not to wet it much,

compartments 29 and 36 may contain Very 3 gases generated in the several chambers of" compartment 31 being trapped by'the solution are exhausted or Withdrawn from: said compartments by a suitable suction apparatus through openings 38: and 34 I By the abovementioned process and apparatus there is obtained a poroussilicious substance impregnated with basic or alka line matter and carbon in intimate mixture, and this is used as a flux, a support for the ore or metal charge in the smelting furnaces, a purifying agent, and a carburizing agent, and it also renders the charge penetrable by gases. This material can be used in the place of the lime orcoke when fluid fuel is used, and as it can be used repeatedly, it effects a great economy, especially where lime is not easily available. It is particularly advantageous .when a fluid fuel is used, or where c'oke'is scarce or high in price. 7

In the smelting of pigiron or scrap'by means of hydrocarbons or fluid fuel, it is difficult to impart to, or even to retain in, the iron a desirable amount of carbon when said iron is fused. This is caused-mainly by the oxidizing action 'in reference to iron when said fuels are used. If, however, a material such as herein described, containing, or forming or capable offorming a carbonate of'the alkali-metals, .be used to hold upthe charge, said carbonatesbeing non-volatile at the high temperature necessary to carry out the process, their joint ac tion, together with the carbon and nitrogen involved, maintains a reducing atmosphere in the Zone of fusion, or, what amounts to the same thing,the gases involved are maintained suflicientlycarburizing in this Zone, to impart to the iron the necessary carbon. By the term re-ag-entiin the claims is meant any substance which will re-act with the slagging agent which is being treated. In general, this will be of a'basic character, such as lime, sodium or potassium carbonate, feldspar, fluorspar, and so on, but it may also be of an acid character, as when it is desired to treat ores for anexcess of lime, or other bases therein. 7 V

When; the, hot puffed slag is passed through the chamber 29, said chamber containing only a small amount of the alkaline solution, or even none at all, said porous slag will retaln sufficient heat to. coke the hydrocarbons which are conta1ned;1n its pores when movec. in and through the cham ber containing said hydrocarbons. In such case, it is not necessary to further heat said puffed slag in a. separate coking chamber.

Whereas in certain of the claims I have used the expression oil. it is to be'understood that this expression is intended to in clude hydro-carbon which although solid at ordinary temperatures becomes liquid when sufficiently heated so as to be capable of being injected into the portions of the silicious substance. I Y

By the term charge I mean the metalliferous material usually containing a an 'ue a reducin f a entjandadditional basic or acid material which, in conjunction wlth the herem mentioned flux, and said gangue produces a slag of proper constituency.

By the term puffing agent is meant any known material, generally of'aqueous nature, which being forced into, through, or coming in contact with said molten silicious substance will cause the same to become porous.

I claim '1. The process which consists in heatingin a blast furnace materials-whiclrwill, when molten, produce a slag containing a carbon ate of the alkali metals and molten iron, conducting molten iron and slag from said furnace into a heated chamber, forcingsuperheated steam and air onto said molten slag as it floats on said molten iron to purify the same and withdrawing said purified molten slag.

2. The method of preparing a fluxing material which consists in heating a metallic bath and molten slag floating on the same.'

applying superheated steam and air to said slag to purify the same, II1OV111I said purified molten slag in a stream and simultaneously forcing gaseous material from beneath the moving stream thru said molten slag to pull the sameforthe purpose described.

3. The process which'consists in making porous a molten silicious substance, introducineliquid hydrocarbons into the pores of said substance and expelling the volatile elements of said hydrocarbons' by means of purify the same, withdrawing themolten purified slag from said chamber, forcing fluids through said molten slag to make it porous when congealed, and introducing into the pores of said congealed porous slag terial capable ofre-acting therewith.

' 6. The method of preparing a flux which method, includes the placing: of a purified congealed slag in proximity to a chargefin'a smelting furnace, heating; saidcharge and slag, withdrawing molten metal and slag,

from said furnace and conducting the same into a heated chamber, forcing superheated steam and air onto the molten slag floating; on the molten metal in said chamber, simul-v taneously and separately withdrawingmolten metal and slag'and congealing said purified slag'for the purpose specified. i

7. The process which consistsin conductingmolten iron and slag from arblast fur nace into a heated chambenrforcing super-' heated steam and: air onto the molten sla to purify the same, making said molten slag porous, introducing hydrocarbons into the pores of said porous slag'and heating said slag in a coking chamber or the like to fix the carbon of said hydrocarbons in thejpores of said slag. f

' 8. The process which consists in smelting materials producing a slag containing a carbonate of the alkali metals and iron, conducting said slag into a heated chamber,

forcing oxidizing fluids onto said slag as it floats on the molten iron in said chamber to purify the same, making said purified slag porous, introducing hydrocarbons in the pores of said porous slag and heating said slag in a coke oven to fix the carbon of said hydrocarbons in said pores.

9. The process ofmakinga porous silicious substance containing in its pores solid carbonaceous material which consists in forcing a puffing agent into contact with said silicious substances when in a highly heated condition to render the same porous and then passing said heated porous substance through heated hydrocarbons. n

10. The process of making a porous silicious substance containing in its pores solid carbonaceous material which consists in contacting said silicious substance when in a highly heated condition with a puffing agent to render said substance porous, passing said heated porous substance through heated hydrocarbons and expelling the volatiles of said hydrocarbons by means of heat 'in a coking chamber. p

11. The process of preparing a silicious material for fluxing and other purposes which consists in forcing a pufiing. agent into said material when in a highly heated condition to form pores therein, passing said porous heated material through an alkaline solution and heated hydrocarbons and then heating said porous material in a coking chamber to expel the Volatile constituents, of

said hydrocarbons.

12. An apparatus for forming a fluxing material comprising a receptacle for the fluxing material in a highly heated condition, conduit leading therefrom, a perforated table to which said conduit leads, means for forcing a puffing agent through the perforations of the table and into the material, receptacles for an alkaline liquid,

and oil and means for conducting. the material through said receptacles in succession.

13. An apparatus for forming a fiuxing material comprising a receptacle for the fluxing material in a highly heated condition, a conduit leading therefrom,- a perfo rated table to which said conduit. leads, means for forcing a pufling agent through the perforations of the table and into the material, means for cutting the material into pieces, means for separating the pieces of from a furnace into said receptacle, means.

for withdrawing metal and slag from said receptacle, a conduit'leading therefrom, a perforated table to which said conduit leads, means for forcing a putfing agent through the perforations of the table and into the material, a receptacle for oil and means for' conducting the material through said receptacle. I

15. An apparatus for forming a fluxing material comprising a receptacle for the flu xing. material in a highly heated condi tion, means for heating said receptacle, means in said receptacle to force steam and air on to said material, a perforated table, a conduit leading from said receptacle on to said table, means for regulating-the flow'of said material from said receptacle, means for adding material to said fluxing material as it flows, means for forcing a pulling agent through the perforations of the table and into the material, means for cutting the material into pieces, means for separating the pieces of the material, receptacles for an alkaline liquid and oil, means for conducting thematerial through said receptacles in succession and means for preventing the'fr'ee escape of gases from said receptacles.

16. Anapparatus for forming a fluxing material comprising a receptacle for the fluxing material in a highly heated condition, means for heating said receptacle, a conduit leading therefrom, 'a' perforated table onto which said conduit leads, means for forcing a pufling agent through the. perforations of the table and into the material,

.means for cutting the material into pieces, -means for separatingthepieces of the material, receptaclesfor an alkaline liquid'and 011, means for conductlng the material through said receptacles 1n succession and means for preventing the free escape of pieces While beingv moved and means for cooling said material moving and cutting' means.

of material for fluxing and other purposes in combination with a blast furnace, a conduit leading therefrom, a chamber into which said conduit leads, means for heating said chamber, means for forcing gaseous material onto molten slag floating on molten metal in said chamber and means for emptying said chamber.

19. An apparatus for forming a fiuxing material comprising a receptacle for said fluxing material in a highly heated condition, means for heating said receptacle, means to conduct molten metal and slag from a furnace into'said receptacle, means for Withdrawing metal and slag from said receptacle, a conduit leading therefrom, a perforated table to Which said conduit leads, means for forcing gas through the perforations of the table and into the material,

means for cutting said material into pieces, a receptacle for the alkaline fluid aIId'OIl, means for moving the material into the receptacle, means for conducting the mate-' rial through said receptacle and means for coking said material.

20. An apparatus for forming a fluxing material comprising a receptacle for said fiuxing material in a highly heated condition, means for heating said receptacle,

means to conduct molten metal and slag from a furnace into said receptacle, means for wlthdrawing metal and slag from sald receptacle, a conduit leading therefrom, a

perforated table to which said conduit leads, means for forclng gaseous material through the perforations of the table and into the material, means for cutting said material into pieces, a receptacle for the alkaline fluid and oil, means for moving the material into the receptacle, means for conducting the material through said receptacle means for coking said material and means for cooling said cutting means. a

JOEL, LUND. p, 

